Pile fabric and method



Oct. 17, 1961 H. F. NOWICKI ET AL 3,004,564

PILE FABRIC AND METHOD 2 Sheets-Sheet 1 Filed June 2, 1960 FIGZ.

FIG.4.

mvzm-ons HENRY F NOWICKI HARRY J. SMILEY Oct. 17, 1961 H. F. NOWICKI ET). 3,004,564

PILE FABRIC AND METHOD Filed June 2, 1960 2 Sheets-Sheet 2 FIG .7.

INVENTORS. HENRY F. NOWICKI HARRY J SMLEY a ATM.

This :invention relates :to .the iweavingsofrpile fabrics and more particularlyto an improved Wilton-velvet floor covering.

: Infithe zpresent vogue for sculptured floor ;coverings 3 161391 .ardfimal dfq 'iflbl'iiliin Whi h t ei h Ofthe gpile in selected p areas can be ,controlledxto a .pluralityof ;le.vels to ;.enhance the. appearance ofrthe fabric and also to provide increased resiliency and resistance to wear. In the well-known Wilton type fabric different colored yarns are carried completely buried in the backing until called for by the jacquard to weave over the pile wires, thus creating the desired appearance or design due to the color selection. Modern decorating trends are towards the monotone or selftone fabrics which do not rely upon color dilferences to create the design in a single level fabric. The utilization of the jacquard mechanism to create multi-level pile effects of as many ditferent types as possible is an important factor in todays production of pile floor coverings.

The present invention achieves a three-level pile fabric having a dense raised ground and the height of the pile yarns may be controlled so that selected pile yarns are carried over the various different heights or types of pile wires to provide the artistic appearance of the fabric which is not dependent upon color differences alone.

A primary object of the present invention is to provide a jacquard controlled Wilton type fabric having a raised pile ground consisting of intermediate height pile.

A further object of the invention is to provide a novel method for producing a cut and uncut Wilton type pile fabric.

A further object of the invention is to provide jacquard selected yarns for weaving over wires of one character and harness controlled yarns for weaving over pile yarns of a different character.

Further objects will be apparent from the specification and drawings in which:

FIG. 1 is a perspective showing a pile fabric woven in accordance with the present invention,

FIG. 2 is an enlarged sectional detail as seen at 2-2 of FIG. 1,

FIG. 3 is a section as seen at 33 of FIG. 2,

FIG. 4 is a section as seen at 4-4 of FIG. 2, and

FIGS. 5-7 are sectional views similar to FIG. 2 showing variations in the weaving of a fabric in accordance with the present invention.

In the production of a Wilton type fabric certain yarns are controlled by means of lingo heddles actuated by the conventional jacquard pattern mechanism. In a velvet type fabric the pile yarns are controlled in groups by means of harness frames which simultaneously raise and lower a large number of individual heddles secured in the harness frames. In the present instance it is desired to simultaneously control one frame or series of yarns in each dent by means of harnesses or alternatively by means of a separate set of lingo heddles all actuated simultaneously. One or more additional pile yarn ends in each dent are then controlled by the jacquard to run dead in the ground fabric or to work over pile wires of a different type, preferably cutting wires, if and when selected by the jacquard.

In FIGURE 1 there is shown a textured or sculptured Wilton fabric having completely random areas of high pile, regular areas of high pile, and a raised pile back- Unite-d States PatentfO lice 1 .Ratented Oc t. 17.,,19.6.1

. .-1 .however,..jthe low pile has been emphasized r.to more .clearly illustrate .:.its ,presencethroughout .the

. enti re'fabric. ,FIGUREZ clearly showsa crosssection of the constructiomof our improved fabricand it .will be seen .that the ,fabric 318 of the .usual .doublje plane -Wilton -.type having ,stutfer warps 10, :10,- upper filling .,wefts or -.,shots ,11, and bottom .filling ,wefts or shots .12. The .uppenshots .11 and bottom shots ,,12.are .boundprtied 1together,b,y means of ,chainwarps 13 and 14 which are interwoven therewith in conventional manner. In the present example each dent, which isthe spacebetween adjacent pairs of chain warps 13 and 14, carries a set ;of jacquard pile yarns designated as frame 15, a second set of jacquard pile yarns designated as-fra'm'e -16,-and -a set of velvet pile yarns shown as frame 17. Frame 15 comprises pile yarns which are tied in under alternate top shots 11 shown in the lefthand portion of FIGURE 2 or the frame may run dead between top shots 11 and bottom shots 12 as shown in the middle portion of FIG- URE 2. Both frames 15 and 16 are jacquard controlled and, therefore, they can be raised over the pile wires 20, 20 of the high pile wire set whenever it may be desired to do so. Preferably the high pile wires 20 will be of the cutting type as shown in FIGURE 2 so that theraised pile on the carpet will be a plush or cut type and preferably the intermediate pile as formed by frame 17 will be uncut. The intermediate pile is woven over the pile wires 21, 21 which after withdrawal produces the fabric of the type shown in FIGURES 1 and 3. Likewise the lower wires 21, 21 may be cutting, non-cutting, or undulating in order to achieve still further texturing effects.

In FIGURE 5 further variations are shown in which the high wires 20a are undulating so that the high pile is uncut but of varying heights. A further modification is shown in that frame 15 may be selected to weave over lower wires of the same height as the wires 21, 21. Frame 17 always weaves over alternate wires if it is harness controlled. The alternate wires, however, may be chosen ofdiiferent characteristics and the types of wires both for the high and the low areas of the fabric may be planted to provide any desirable repetitive sequence of wire characteristic.

The use of low cutting wires for frame 17 in conjunction with high cutting and/or wavy wires is shown in FIG- URE 6. It will be noted, however, that in accordance with the present invention frame 17 does not at any time run dead in the ground fabric but is carried up over every alternate pile wire regardless of the type of this pile wire and is tied into the top row of filling shots under every other weft. Frames 15 and 16, however, regardless of the type of wires over which they weave can be controlled by the jacquard cards to run in the ground fabric for as long as may be desired. FIGURE 7 again shows frame 17 weaving over alternate intermediate height pile wires 21, 21 and tied in under every other top shot 11. Frame 15, however, is additionally controlled to weave over selected top shots such as 11a and 11b but under the associated high pile wire 20b, 20b. Frame 16 can also be controlled to weave between the top filling wefts 11 and the pile wires 20. This jacquard controlling of the patterning high pile permits the provision of a wide variety of sculpturing effects while at the same time achieving an unusually firm and resilient ground fabric employing a minimum of pile yarn.

It will be understood that the present invention provides a wide variety of choice in the appearance of the fabric and also it is crush resistant. The constantly working ground pile yarns typified by frame 17 insure adequate coverage of the ground fabric and greatly enhance theresiliency.

Having thus described our invention,

1 Themethod'of'weaving ajthree-frame Wilton fabric having 'filling'wefts; binderw'arps, and ground warps jwhichcomprises the steps of controlling all the' yarns in one of the frames'to weave pile projections over a1- ternate rows of filling Wefts, and controlling the other two frames of 'pile'yarns to selectively weave higher pile projections over intermediate filling Wefts.

2; 'I'he'method of claim 1 in which the yarns of the itirst frame are tied in under alternate top filling shots.

3. The method of claim 1 in which the intermediate pile yarns are woven to a constant uniform height and the yarns of the second and third frame are selected to run dead in the ground fabric or to form higher pile projections than the intermediate pile projections.

A 'Wilton pile fabric, having ground warps, filling wef ts, and at-least two f rames of .pile warps in which 20 References Cited in thefile of this patent UNITED STATES PATENTS' 760,985- Hardwick Ma .24, 1904 2,121,909 r June 28, 1938 

